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Anhydro Spray Drying Plantsfor the Dairy Industry

A Question of Accuracy,Efficiency, and FlexibilitySpray DryingC R I T I CA L C U S TO M E R D E M A N D SSpray drying is a highly cost-effective methodPlant solutions for dairies looking for long-term competitive leadership andof obtaining powder from heat-sensitive liquidsprofitability need to meet a long line of decisive demands. These include:such as milk and whey while retaining valuablenutrients, aromas, and flavours.Spray drying is a continuous process, whichconverts almost any pumpable liquid into a freeflowing powder. The liquid, which can be preheated in order to reduce energy consumptionin the drying process itself, is sprayed via anatomizer into a drying chamber, in which itis evaporated. The solids content is further Constant product quality and unifor mity with consistent powder moisturecontent and particle size distribution. High yield at lowest possible cost. The ability to utilize the same plant for a number of different applications. Traceability and compliance with food regulations. New product developments with short time to market.processed in an integrated and/or external fluidbed.B E N E FITSThe Anhydro spray drying plants are available in a wide range of sizesand configurations. All are based on experience gained from long-termSPX FLOW, Inc. (NYSE:FLOW) is a leadingmanufacturer of innovative flow technologies,many of which help define the industry standardin the market segments they serve. From itssolutions for critical demands: Total control over a wide range of para meters such as moisture content,headquarters in Charlotte, North Carolina, itparticle structure, particle size and distribution, solubility, mixability, andoperates a sales and support network, centreswettability, and retention of natural aromas and flavours.of manufacturing excellence, and advancedengineering facilities, throughout the world. Itscutting-edge flow components and processequipment portfolio includes a wide rangeof pumps, valves, heat exchangers, mixers,homogenisers, separators, filters, UHT, and dryingtechnology that meet many application needs.Its expert engineering capability also makes it apremium supplier of customized solutions andcomplete, turn-key packages to meet the mostexacting of installation demands.Incorporating many leading brands, SPX FLOWhas a long history of serving the food andbeverage, power and energy, and industrial marketsectors. Its designs and engineered solutionshelp customers drive efficiency and productivity,increase quality and reliability, and meet the latestregulatory demands. In-depth understandingof applications and processes, state-of-the-artInnovation Centers, and advanced pilot/testingtechnology further assist in optimizing processesand reducing timescales to reliably meetproduction targets.To learn more about SPX FLOW capabilities,its latest technology innovations and completeservice offerings, please visit www.spxflow.com.2partnerships with dairies all over the world in order to provide competitive Energy-efficient components, continuous and rapid drying, ease ofoperation, and process automation deliver maximum process yield at thelowest possible cost. Top-quality and reliable components for prolonged service life togetherwith efficient and straight forward CIP (cleaning-in-place) mean maximumuptime. Automated process control enables end-to-end traceability in compliancewith contemporary food standards and regulations. Plant designs based on experience with many different applications ensureversatility for a variety of applications.

Atomization and DryingTypical Product ApplicationsA N H Y D R O ATO M I Z E R SSPX FLOW offers two basic types of atomizers which disperse feedliquid into the hot air in the drying chamber:With the Anhydro spray drying equipment youcan produce a wide range of dairy powders. Centrifugal atomizers, whichaccelerate and atomize theliquid feed using centrifugalforce in a rotating disk.They are suitable for mostdairy applications, especiallyInfant Formulacrystallized products.Qualities such as easydosing, good reconstitutional Nozzle atomizers, which forceproperties, dustless powders,the liquid feed through aand high nutritional values arenozzle under high pressureobtainable.or using compressed air.Nozzle atomization is usedMilk Powderin particular when a coarseDrying of milk into powders,powder with narrow particlewhere aromas, flavours, andsize distribution is required.At o m i z e rCC 400colouring as well as protein,fat, carbohydrate, vitamins,minerals, etc. are retained.Concentrated WheyAs a by-product of cheesemaking, whey can beprocessed to make a widerange of value-addedproducts, e.g. whey proteinconcentrate.IngredientsTee and coffee creamer,chocolate milk, and buttermilk.Nozzle atomizer3

A N H Y D R O S P R AY D RY E R STwo drying principles are relevant for the dairy industry. TheAnhydro Conical Spray Dryer (CSD) with air outlet at the baseof the chamber, and the Anhydro Triple-A Spray Dryer with airoutlet at the top of the chamber.Each type offers the following options: Single-stage spray dryers with product outlet at the base. Two-stage spray dryers sending product to an external fluidbed dryer and/or cooler. Multi-stage spray dryers sending product to an integratedfluid bed, and then into an external fluid bed dryer and/orcooler.A s e c t i o n o f a d a i r y d r y i n g s y s t e m - a d r y i n g ch a m b e r c o n e a n d abag filter bottomF I N E S R E - I N J E CT I O NFines are led back from the cyclones and/or bag filters to theatomization zone or integrated fluid bed for agglo meration.Dryingch a m b e rOil/gasheaterCycloneFilterPr o d u c t f e e dFluid bedPo w d e r s i l o sMain airA t y p i c a l d a i r y f l o w d i a g r a m u s i n g An h y d r o Tr i p l e - A S p r a y D r y e r4

Gentle and Efficient FinishingTemperature and residence time in the spray drying chamberAdditional drying using one or more A nhydro fluid beds adds aare important parameters affecting powder consistency and thenumber of advantages compared to single-stage spray dryingretention of nutrients, flavours, and aromas.e.g.:After-drying of powder is typically used for heat-sensitive Energy savings due to a high tempe rature difference in theproducts and for obtaining a free-flowing powder.dryer. Improved product quality, in particular in heat-sensitiveFLU I D B E D SAn integrated or external fluid bed can be used for after-dryingand/or cooling of powder leaving the drying chamber withrelatively high moisture content. Use of a fluid bed enablesproducts, due to a more gentle drying process. Higher powder bulk density and l ower air content due to lowerdrying temperature. Lower powder loss due to reduced powder content in the air.adjustment of process parameters in order to achieve a superioroverall drying economy and powder quality. An external fluid bedR E W E T AG G L O M E R AT I O Nis also ideal for other kinds of powder treatment such as mixing,Anhydro fluid beds are also used for rewet agglomeration foragglomeration, dust binding, and instantising.the production of coarse and stable agglome rates as well asadding atomized additives. Typical examples are the productionof instant skim-milk and whole milk powders. Agglomerationresults in better free-flowing properties, less dust, and improvedsolubility and wettability.A section of a dairy drying system - a fluid bed and a crystallization conveyer5

Optimised Yield and EfficiencySeparation of powder from the hot air leaving the dryingP R O C E S S AU TO M AT I O N A N D C O N T R O Lchamber increases yield by limiting powder losses, andAutomated process control is essential in order to optimiseensures compliance with environmental legislation by reducingkey process settings such as feed rate, temperature, pressure,emissions. Efficient heat recovery is also a key factor in plantresidence time, particle size, moisture content, bulk density, etc.economy.The Anhydro spray drying plant is controlled from numbersof operator stations, providing the operator with an end-to-CYC L O N E Send overview of all production parameters. Anhydro controlPowder from the drying chamber is fed to two or more high-systems also enable plant performance optimization, rapidefficient cyclones for primary separation from the drying air. Withtroubleshooting, and real-time recording of critical process datahigh separation efficiency the cyclones ensure minimal powderproviding complete traceability. Process data can be passed onloss. Further cleaning of the drying air can be achieved by usingto a local network or even to a remote computer via a dedicateda bag filter. This secures that the emissions will be within thedial-up line or the internet.limits of environmental regulations.BAG F I LT E R SAnhydro CIP-cleanable bag filters to replace cyclones enablelower pressure loss and increased energy savings. The filtermaterials can handle relatively high air outlet temperatures, andthe automatic cleaning system ensures a high and constantseparation efficiency.H E AT R E C OV E RYSPX FLOW can offer a number of heat recovery systemsincluding conventional heat recovery system from air exhaust toair inlet.Today more and more systems are utilizing waste energies.Many of the systems like dehumidification system use heatpumps on different levels to optimise energy utilization andenergy cost.Each heat recovery system will be tailor-made to the actualpurpose depending on products, capabilities, and energy costlevels for different energy sources, etc.6A screen-dump example of a typical spray drying plant

Global Services for Individual NeedsC U S TO M E R F O C U SI N N O VAT I O N C E N T R ESPX FLOW can assist in designing complete spray drying plantSPX FLOW’s state-of-the-art test facility close to Copenhagensolutions and optimising process parameters as well as plantin Denmark enables customers to perform confidential productmaintenance and spare parts services.development and trials together with knowledgeable SPX FLOWThe SPX FLOW worldwide service organization is ready toprovide any necessary spare parts at short notice. Our servicetechnicians can help you rectify problems on site, thus reducingunscheduled downtime to a minimum.SPX FLOW offers a number of service agreement options,technologists on drying and evaporation equipment ranging fromlaboratory-scale testing to full-scale pilot production runs. Hereit is possible to test applications and processes, thus ensuringfast time to market with optimised performance immediatelyafter commissioning. Small plants are also available on a rentalbasis for in-house laboratory trials.depending on your individual needs, and our service engineersare always available to provide application and developmentsupport.S PX F LOW i n n o v a t i o n c e n t r e i n S o e b o r g , D e n m a r k7